Device for winding continuous winding with interlay sections

ABSTRACT

A device for winding continuous windings with interlay sections mainly for transformers and the like. The device is characterized in that it is provided with a rotatably mounted base adapted to accommodate thereon a circumferential arrangement of bearing members used as a mandrel for laying the wire of the section being wound, and drives for effecting a step-like reciprocation of the bearing members in a radial direction with respect to the base.

Aug. 7, 1973 United States Patent [191 Goldman et a].

[ DEVICE FOR WINDING CONTINUOUS m a Z n a W h c S n m6 an T rm m ms R em H wa B A H mm mE y M r mm H '0 HA 5 .3 m flm m lu D h m ahhM T C 7M6, E050 S GQMWR nmmm s L m hmW R nwk U E a m y T mflmok m &w am u m wwm T nmeeo l wmw mw w LKESZ N m I O m m w W m H r i [22] Filed: Oct. 15, 1971 A device for winding continuous windings with interlay 1 Appl No: 189 590 sections mainly for transformers and the like. The device is characterized in that it is provided with a rotatably mounted base adapted to accommodate thereon a [52] [1.8. 140/921, 72/148 circumferential arrangement of bearing members used [51] Int. 82 3/08 as a mandrel for laying the wire of the section being [58] Field of Search..................... 140/922; 72/146,

wound, and drives for effecting a step-like reciprocation of the bearing members in a radial direction with respect to the base.

[56] References Cited UNITED STATES PATENTS 7 Claims, 12 Drawing Figures 2,140,137 12/1938 Merkle. ........140/922 PATENTEU M18 7' 3. 750,7 1 9 sum 1 or 4 PATENTED AUG 1 5 sum 2 OF 4 PATENTED M19 71973 SHEET 3 [IF 4 PATENTEB M19 71975 SHEU t 0F 4 III! DEVICE FOR WINDING CONTINUOUS WINDING WITH INTERLAY SECTIONS The present invention relatesto equipment for use in the manufacture of transformers and, more particularly, to devices for winding continuous windings with interlay sections for power transformers and reactors.

By an interlay section is meant a section which is wound from the outer coil to the inner one.

There is a known device for effecting windings with interlay sections, comprising a mandrel adapted for winding said section and constituted as rollers serving as bearing elements for the'wire being wound, said bearing elements being mounted circumferentially in a coaxial relationship with the mandrel, the latter being provided with stationary bearing elements for sections being wound from the inner to the outer diameter, while for the purpose of laying the wire over the section height provision is made for a means fashioned as a roller having an individual drive and mounted at right angles to the bearing rollers above the latter.

The winding mandrel with the stationary bearing elements is provided with means for driving it in rotation.

The bearing rollers are incapable of displacing elements circumfcrentially, however, each of them can freely rotate about its respective axis, and the wire rolls on the bearing rollers in the course of winding a turn.

The supply of wire to the zone of the bearing rollers is effected at a certain angle. A horizontal position of the wire in the section is provided due to the presence of an individually driven guide roller ensuring both variation in the wire direction and, to a certain extent, the supply of the wire.

This known device has been disclosed in G.D.R. Rap-, tent No. 15509, class 2l d 49.

The known device operates in the following manner: a section to be performed from the inner diameter to the outer diameter is wound onto the mandrel with stationary bearing elements with the wire tensioned, then, a transition is effected to the section being wound from the outer diameter to the inner diameter, spacer pieces are mounted and, by pressure-supplying the wire to the zone of the rolling elements viz'. rollers mounted on the circumference, i.e., at the inner diameter of the given circumference, sections are wound from the outer diameter to the inner diameter. While so doing, the bearing rollers serve as the diameteral support of the first (outer) turn, and the earlier wound turns serve as the support for the subsequent turns.

This known device is disadvantageous in that the interlay section is wound with the wire supplied to the mandrel under pressure. This impairs the quality of winding of the-interlay section, for the lack of tension in the wire results in a rather loose mating of the wires with gaps therebetween.

The use of the known device precludes the possibility of winding sections with a flat low-thickness wire which is likely to be deformed in the course of winding.

In addition, the known device calls for the use of a mandrel provided with stationary bearing elements to wind sections from the inner diameter to the outer diameter, as well as for an additional operation of tightening the coils of the interlay section.

Moreover, the likelihood of the deformation of the wire supplied to the mandrel under pressure rules out the possibility of employing high speeds of mandrel rotation in the course of winding.

The afore-listed disadvantages are most apparent when winding large-diameter windings where the wire has a low curvature at the outlet from the guide chute, while the operating conditions of such windings in highpower transformers place heavy requirements upon the quality and density of mating of adjacent turns and the section as a whole.

Low buckling stability of the winding wire precludes the possibility of high pressures along the wire axis and, consequently, the foregoing requirements cannot be met.

Additionally, the transition in the course of winding from tensioning the wire to exerting pressure thereupon brings about complications in the winding manufacture.

The afore-listed disadvantages prohibit an extensive use of the afore-described known device, and the majority of transformer-producing companies employ a technology involving manual interlaying of sections, hence the term interlay is used for the sections in which the turns are positioned from the outer diameter to the inner diameter.

It is an object of the present invention to develop a device for mechanized winding of continuous windings of any diameter with interlay sections, providing for the winding of both interlay sections and sections being wound from the inner diameter to the outer diameter at a constant tension of the wire.

Another object of this invention is to provide for a high density of mating the adjacent turns and the entire section when winding continuous sections.

In addition, one of the objects of the present invention consists in the development ofa device for winding continuous windings with interlay sections wherein bearing members for the wire being wound are common for both the turns of sections wound from the inner diameter to the outer diameter and for the interlay section turns, in both said cases said bearing members being arranged inside the turn but not on the outer diameter thereof.

In the accomplishment of above objects there is provided a device for winding continuous windings with interlay sections, comprising bearing members which have drive means and serve as a mandrel in the course of winding the section wires, and means for laying the wire within the height of the interlay section when winding the turns thereof, and according to the present invention, there are provided a rotatably mounted base which carries said bearing members circumferentially arranged thereon, and a drive means is for effecting a step-like reciprocation of the bearing members in a radial direction.

It is expedient for each radially-movable bearing member to be provided with a respective drive means.

The device according to the invention can be provided with a winding mandrel having stationary bearing members mechanically connected to the rotatable base, while both said rotatable base and winding mandrel with the stationary bearing members can have respective drives interconnected kinematically to provide for synchronous rotation of the mandrels with the stationary and radially-movable bearing members.

The device of the present invention for winding continuous windings with interlay sections is simple in design, convenient in operation, ensures a high quality of the resulting windings and high winding efficiency, and helps produce windings with interlay sections both when using a mandrel with stationary bearing members and without said mandrel.

Other specific features and advantages of the present invention will become apparent from the following detailed description of the structure and operating principle of a device according to the invention, with a mandrel provided with radially-movable bearing members, disclosure is also made of a possible embodiment using a device with two mandrels, the bearing members of one of said mandrels being stationary.

In the appended drawings:

FIG. 1 is a cross-sectional view of an embodiment of the device according to the present invention;

FIG. 2 is a plan view of the device of the invention with parts broken away and in section;

FIG. 3 is a view along arrow A of H02, illustrating the relative position of the means for laying the wire, a wound turn and the starting wire;

FIGS. 4, 5, 6 illustrate sections of the device as shown in FIG. 2 in the place of laying the wire, taken on lines IV-IV, VV, and VIVI, respectively;

FIGS. 7, 8, Q, 10 diagrammatically illustrate the operation of the extensible bearing members of the device, show the sequence of laying the turns of the interlay section;

FIG. 1 1 illustrates diagrammatically the operation of winding of the section from the inner diameter to the outer diameter, using the same bearing members, in the case when the winding is wound without the aid of a winding mandrel; and

FIG. 12 is a perspective view, partly broken away, which illustrates the position of the bearing members at the beginning of winding the interlay section turn that is second in relation to the outer diameter.

Referring now to the drawings, the device according to the invention is essentially constituted of a mandrel comprising bearing members 1, 2, 3, 12 arranged at a required diameter D (cf., FIG. 2) on a rotatable base 13 (it should be noted that the number of the bearing members is shown to be twelve for exemplary purposes and is optional). All the bearing members are ofa similar design and are designated 1 to 12 for better clarity of the diagrams shown in FIGS. 7, 8, 9, 10.

The bearing members 1 to 12 are connected by means of rods 14 to a drive 15. The drives 15 are secured on the rotatable base 13 and operate in accordance with a preset program to perform the following functions:

a. to periodically displace the bearing members 1 to 12 in a radial direction towards the winding axis by a distance greater than the thickness of wire in the wire laying zone indicated by angle B in FIGS. 7, 8, 9, 10;

b. to press the laid wire against the outer turn with a particular force in a direction indicated by arrow L at the exit from the laying zone B,

The drive 15 may be, for example, a hydraulic cylinder performing the afore-listed functions according to a preset program. Programming devices which provide for the actuation of the drive elements connected in the common circuit are well known and no description thereof is provided in the present specification.

The rotatable base 13 with all the units accommodated thereon is mounted on rollers 16 (cf., FIG. 1) secured on supports 17. The supports 17 are uniformly arranged in a circumferential array and are attached rigidly to the rotatable base 13.

By means of a drive 18 and transmission 19, the base 13 rotates synchronously with a winding mandrel 20 secured on a faceplate 21 of the winding machine. The rotation of the base 13 can also be obtained by a rigid connection thereof with the winding mandrel 20 or with the faceplate 21.

Arranged beneath the rotatable base 13 is a wire laying unit comprising a wire laying means 22 (FIG. 12) connected by a rod 23 to a supply unit 24. The supply unit 24 is rigidly attached to the foundation by means of a support 25 (FIG. 1) and constructed, first, for an intermittent feed of the wire lay ing means 22 is a radial direction towards the winding axis by a distance not less than the wire thickness after one or more revolutions of the rotatable base 13 and, second, for a rigid fixation of the wire laying means 22 in the displaced position for the time of one or more revolutions of the rotatable base 13.

The unit 24 can be, for example, a hydraulic cylinder incorporated in the overall system of the drives of the bearing members and performing the afore-mentioned functions according to a preset program.

As seen from FIG. 3, the surface H of the wire laying means 22 directs a starting wire 26 at an angle a to the plane of the disc of the section being wound and blends smoothly into a plane parallel to the plane JJ in sectron.

As seen from FIGS. 2 and 12, the bearing members 1 to 12 are positioned so as to be placed between cardboard racks 27 of the winding and spacer pieces 28 secured on said racks. The thickness of the cardboard rack 27 such bearing members 1 to 12 is selected to be less than the thickness of the cardboard rack 27 such that the bearing members, during winding of the last turn of the interlay section, can be accommodated in the space defined by the last turn and the surface of the winding mandrel 20 with some clearance required for the removal of the bearing members from the sections of the winding.

The drives 15 together with the bearing members 1 to 12 can be adjusted on the rotatable base 13 to a preset diameter of the winding being wound, the diameter of the bearing members depending upon the outer diameter of the section minus two thicknesses of the wire.

In a similar manner the unit 24 is adjusted so that the surface of the wire laying means 22 assumes the same position with respect to the section diameter or somewhat less than that.

The device of the present invention operates in the following manner.

The wire 26 istransferred to the bearing members 1-12 from an adjacent section wound from the inner diameter to the outer vone. The starting wire 26 is directed over the surface H of the wire laying means 22 at an angle to the plane of winding, the tangential start of the wire onto the bearing members beginning at point M (FIG. 2) removed on the arc of the diameter D by such a distance as to insure clearance between the plane of winding and the face end of the starting wire.

The faceplate 21 of the winding machine, together with the winding mandrel 20 arranged thereon, are driven in rotation in the direction of arrow K (FIG. 2) synchronously with the base 13 and all the units secured thereon. While so doing, the first turn of the interlay section starts to be wound onto the bearing members l to 12 and on the winding mandrel. The starting wire 26, while being tension-wound onto the bearing members, slips with respect to the surface H of the wire laying means 22 and is laid by the latter means onto the plane of winding. Before the wire transfer from the adjacent section serving as the beginning of the first turn completes a full revolution and approaches point E (FIG. 3) at which it encounters the face end of the starting wire, a command from the program causes the operation of the drives 15 connected with the bearing members 1 and 2 in the zone B (FIG. 7), and said two bearing members displace towards the axis of winding by a distance exceeding that of the thickness of the wire being laid. The starting wire displaces with them, for it is under tension. Simultaneously with the displacement of the bearing members 1 and 2 there takes place the displacement of the wire laying means 22 over a distance equal to or greater than the wire thickness in the same direction under the efi'ect of the unit 24 which has received a command from the program. On having been displaced the specified distance, the wire laying means 22 is fixed rigidly in this position. Thus, there is formed under the beginning of the first turn in the zone B a space in which, upon further rotation of the device, the wire laying means 22 directs the starting wire 26 to begin the formation of the second, inner, turn. This successive laying of the wire is illustrated in FIGS. 4, 5, 6 with the aid of sections taken on the lines IV-IV, VV, VIVI, respectively.

Upon a further rotation of the device, all the bearing members which successively enter the laying zone B in accordance with the program, and are displaced in a manner analogous with the bearing members 1 and 2, by the same distance. This can be seen from FIGS. 8, 9, which illustrate the successive laying of the second turn under the first one.

On having passed the zone b, the bearing members 1-12 are urged radially outwards by initiation of a program command acting, for example, on the valve system of the drive to apply, with a force acting in the direction of arrow L, the laid wire against the outer turn which is already in place (FIGS. 7, 8, 9), thereby pressing the laid turn against the outer turn.

On completing the second turn, all the bearing members will be displaced towards the center of the winding being wound by a distance equal to the wire thickness, while the vacated spacewill be occupied by the second turn.

FIG. 10 shows the beginning of winding the third turn. While so doing, the bearing members 1 and 2 once again enter the zone B towards the axis of winding, the wire laying means 22 is once again displaced and the cycle is repeated. The winding continues until the last turn is laid on the racks 27. At this moment, the bearing members 1 to 12 are in the space between the racks.

After the interlay section has been entirely wound, the bearing members 1 to 12 are caused to shift by a common command from the programming device, towards the center to release the section, and the faceplate 21 together with the winding mandrel and the wound portion of the winding is lowered by a distance equal to the pitch of the subsequent interlay section. At the same time, the unit 24 returns the wire laying means 22 to the initial position. The wire transition is effected, and on the racks 27 a section is wound from the inner diameter to the outer one. There after, a command causes the drives 15 (FIG. 1) to return the bearing members 1 12 to the initial position to the diameter D, and the device is ready for winding the subsequent interlay section.

When using the device without a winding mandrel, the radially-movable bearing members 1 12 are positioned at a preset diameter equal to the outer diameter of the winding minus two thicknesses of wire, such that the bearing members are as close as possible to the faceplate 21 which may essentially be any flat platform loose-fitted on an axle.

The end of wire is attached to the faceplate and the first turn is wound by synchronously rotating the faceplate 21 and the rotable base 13. Winding the turns in the direction towards the center is effected in a manner similar to that described in connection with a device which, in addition to radially-movable bearing members, is provided with a winding mandrel and stationary bearing members, that is, by way of step-like displacement of the radially-movable bearing members.

The wound section rests against the face-plate 21. On winding the interlay section, a transition is effected to a section being wound from the inner diameter to the outer one, and on the interlay section are mounted the spacer pieces 28 in whose slots the racks 27 are placed. After mounting the spacer pieces 28, onto the radiallymovable bearing members 1 12, which have taken a position equal to the inner diameter of the section, there is wound a section from the inner diameter to the outer one. While so doing, the length of the bearing members 1 12 should exceed the height of the two sections.

After both sections have been wound, the bearing members are shifted somewhat towards the center and are disengaged from the sections and, by using the method described hereinabove, the subsequent interlay section is wound with the radially-movable bearing members, the wire laying means having been prearranged in the initial position.

The device of the present invention can be used in combination with horizontal winding benches after slightly modifying its fastening elements.

We claim:

1. A device for forming continuous windings with a number of winding sections one of which is wound from inside to outside wheras the other is wound from outside to inside, said device comprising: a rotatable base ,radially movable bearing members mounted on said base for the winding of wire thereon, means cooperating with said bearing members for winding the wire on the base and rive means for each of said bearing members for locating said bearing members in fixed positions at the beginning of winding to provide a support for the initial turn of wire and for displacing the bearing members from the winding section at the end of winding to facilitate removal of the winding section, said drive means acting on said bearing members to effect displacement of said bearing members during winding to develop a uniform radial pressure upon the wire being wound.

2. A device as claimed in claim 1 wherein said bearing members are circumferentially arranged on said base, said means for winding wire on the base comprising a radially displaceable member extending over a portion of the extent of said base and having a guiding surface for guiding successive turns of wire onto the section being wound, said drive means being operative on said bearing members to displace the same successively as they enter the region where the wire is guided by the radially displaceable member to permit such guiding while the drive means outside said region acts on the bearing members to compress the wire turns against one another.

3. A device as claimed in claim 1 wherein said drive means comprises a separate, respective drive for each bearing member.

4. A device as claimed in claim 1 comprising a winding mandrel, stationary bearing members on said mandrcl, and means mechanically connecting said mandrel for synchronous movement with said rotatable base.

5. A device as claimed in claim 1 comprising a separate drive means coupled to said base to drive the same in rotation.

6. A device as claimed in claim 5 comprising a winding mandrel, stationary bearing members on said mandrel, and means kinematically connecting said base and mandrel for synchronous movement.

7. A device as claimed in claim 4 wherein said stationary bearing members are circumferentially arranged on said mandrel with a spacing to allow said bearing members to enter therebetween when the latter are displaced from the winding section at the end of winding. 

1. A device for forMing continuous windings with a number of winding sections one of which is wound from inside to outside wheras the other is wound from outside to inside, said device comprising: a rotatable base,radially movable bearing members mounted on said base for the winding of wire thereon, means cooperating with said bearing members for winding the wire on the base and rive means for each of said bearing members for locating said bearing members in fixed positions at the beginning of winding to provide a support for the initial turn of wire and for displacing the bearing members from the winding section at the end of winding to facilitate removal of the winding section, said drive means acting on said bearing members to effect displacement of said bearing members during winding to develop a uniform radial pressure upon the wire being wound.
 2. A device as claimed in claim 1 wherein said bearing members are circumferentially arranged on said base, said means for winding wire on the base comprising a radially displaceable member extending over a portion of the extent of said base and having a guiding surface for guiding successive turns of wire onto the section being wound, said drive means being operative on said bearing members to displace the same successively as they enter the region where the wire is guided by the radially displaceable member to permit such guiding while the drive means outside said region acts on the bearing members to compress the wire turns against one another.
 3. A device as claimed in claim 1 wherein said drive means comprises a separate, respective drive for each bearing member.
 4. A device as claimed in claim 1 comprising a winding mandrel, stationary bearing members on said mandrel, and means mechanically connecting said mandrel for synchronous movement with said rotatable base.
 5. A device as claimed in claim 1 comprising a separate drive means coupled to said base to drive the same in rotation.
 6. A device as claimed in claim 5 comprising a winding mandrel, stationary bearing members on said mandrel, and means kinematically connecting said base and mandrel for synchronous movement.
 7. A device as claimed in claim 4 wherein said stationary bearing members are circumferentially arranged on said mandrel with a spacing to allow said bearing members to enter therebetween when the latter are displaced from the winding section at the end of winding. 